INSTRUCTIONS for CONTINUED AIRWORTHINESS and MAINTENANCE MANUAL SUPPLEMENT

or the MMS that describes the modifications during the completion process. (2) If the item refers to an ATA section within the MMS, only ATA number is referenced. For example: Refer to 21-50-00. 6. Reference, Supplemental and Support Documents The following additional reference, supplemental and support documents necessary to properly and safely operate and maintain the components and equipment associated with this MMS, ref. section 21-50-00: Beech Bonanza F33A, A36 and G36 Maintenance Manuals FAA Advisory Circular AC 43-13 USAGE and INSTRUCTION DRAFT A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Issue 3 SECTION II MAINTENANCE MANUAL SUPPLEMENT (MMS) DRAFT A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Issue 3 CHAPTER 00 INTRODUCTION DRAFT A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 1 Issue 3 00-EFFECTIVE PAGES CHAPTER 00 LIST OF EFFECTIVE PAGES Ch-Se-Su Page Issue Ch-Se-Su Page Issue 00 - Effective Pages 1 3 00 - Contents 1 3 00 - Introduction 1 3 DRAFT A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 1 Issue 3 00-CONTENTS CHAPTER 00 – SECTION TITLE TABLE OF CONTENTS Subject Ch-Se-Su Page INTRODUCTION 00-00-00 General 1 DRAFT A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 1 Issue 3 00-INTRODUCTION INTRODUCTION 1. General A. This document contains manual supplement data related to the Beechcraft Bonanza aircraft, models F33A, A36 and G36, as generated during the modification. This section of the supplements includes the Maintenance Manual Supplement (MMS) information used to perform maintenance on the Bonanza aircraft, models F33A, A36 and G36. This MMS contains information necessary to supplement the existing Bonanza Aircraft Maintenance Manual (AMM). B. This MMS for the Bonanza aircraft, models F33A, A36 and G36, is to be supplied with the aircraft modification. Any additional information will be supplied through revisions. C. This manual supplement is controlled by revision issue. The revision log is maintained on the Record of Revisions page of this document. If a temporary revision is issued, it is logged on the Record of Temporary Revisions page of this document. Document revisions are then issued to all operators of equipment using the Service Bulletin form. Service Bulletins are controlled by number and date, and are logged on the Service Bulleting List page of this document. D. Correspondence concerning this publication should be directed to: A/C Systems LLC 138 Sherron Dr. Dickson, TN 37055 Telephone No.: (615) 587-3492 Email: ABlanke681@aol.com DRAFT A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Issue 3 CHAPTER 05 TIME LIMITS / MAINTENANCE CHECKS DRAFT A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 1 Issue 3 05-EFFECTIVE PAGES CHAPTER 05 LIST OF EFFECTIVE PAGES Ch-Se-Su Page Issue Ch-Se-Su Page Issue 05 - Effective Pages 1 3 05 - Contents 1 3 05-00-00 1 3 DRAFT A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 1 Issue 3 05-CONTENTS CHAPTER 05 – SECTION TITLE TABLE OF CONTENTS Subject Ch-Se-Su Page TIME LIMITS-MAINTENANCE CHECKS 05-00-00 1 DRAFT A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 1 Issue 3 05-00-00 TIME LIMITS/MAINTENANCE CHECKS-SCHEDULED MAINTENANCE (ADD) 1. General This section describes the maintenance program for the A/C Systems LLC modifications only, to the Beech models F33A, A36 and G36 aircraft. There are minor changes to this section and the aircraft inspection/checks for this air conditioner modification. Each of the Inspection/Checks listed are based upon time compliance, and when completed, repeat of that individual time interval is to be repeated, either individually, in groups, or collectively. 2. Inspection Interval The following are additional aircraft maintenance checks that have been added for the Air Conditioner System: Reference: 21-50-00 (Page 601) ITEM INSPECTION/CHECK INTERVAL Compressor Belt and Pulleys Check for security, tightness and rotational smoothness and freedom 100 Hrs or Annually Refrigerant Hoses Check for chafing, leaks (oily spots) and security. 100 Hrs or Annually Air Ducting and Vents Check for inlet and outlet obstructions or damage. 100 Hrs or Annually OAT Sensor Check for security and loosness. Check wiring for security, chafing, and condition. 100 Hrs or Annually ECU Check for security and loosness. Check wiring for security, chafing, and condition. 100 Hrs or Annually Evaporator and Condenser Check attaching structure and harware for loosness, damage, and security. 100 Hrs or Annually Receiver/Dryer Check for security and loosness. Check wiring for security, chafing, and condition. 100 Hrs or Annually Condenser Exhaust Screen and Plenum Check plenum for obstructions and security. Check screen for security. 100 Hrs or Annually Condenser Air Intake Screen/Louvers Check for obstructions and security. 100 Hrs or Annually Evaporator Drain Check drain tube for kinks or obstructions. 100 Hrs or Annually DRAFT A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Issue 3 CHAPTER 21 AIR CONDITIONING A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 1 Issue 6 21-EFFECTIVE PAGES CHAPTER 21 LIST OF EFFECTIVE PAGES Ch-Se-Su Page Issue 21 - Effective Pages 1 6 21 - Contents 1 4 21-50-00 1 3 21-50-00 2 4 21-50-00 3 3 21-50-00 4 4 21-50-00 5 3 21-50-00 6 3 21-50-00 7 3 21-50-00 8 3 21-50-00 9 3 21-50-00 10 3 21-50-00 11 3 21-50-00 12 4 21-50-00 13 3 21-50-00 14 4 21-50-00 15 3 21-50-00 16 3 21-50-00 17 3 21-50-00 18 3 21-50-00 19 3 21-50-00 20 3 21-50-00 201 3 21-50-00 202 3 21-50-00 203 5 21-50-00 301 5 21-50-00 302 6 21-50-00 303 3 21-50-00 304 3 21-50-00 305 3 21-50-00 306 6 21-50-00 307 6 21-50-00 308 6 21-50-00 401 6 21-50-00 402 3 21-50-00 403 4 21-50-00 404 4 21-50-00 405 4 21-50-00 406 3 21-50-00 407 3 21-50-00 408 3 21-50-00 409 3 21-50-00 410 3 Ch-Se-Su Page Issue 21-50-00 411 4 21-50-00 412 3 21-50-00 413 5 21-50-00 414 3 21-50-00 415 3 21-50-00 416 3 21-50-00 417 4 21-50-00 418 6 21-50-00 419 6 21-50-00 420 6 21-50-00 421 6 21-50-00 422 6 21-50-00 501 3 21-50-00 502 3 21-50-00 503 3 21-50-00 504 3 21-50-00 505 3 21-50-00 506 3 21-50-00 601 4 A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 1 Issue 4 21-CONTENTS CHAPTER 21 – SECTION TITLE TABLE OF CONTENTS Subject Ch-Se-Su Page AIR CONDITIONING 21-50-00 DESCRIPTION/OPERATION 1 General 1 2 System Description and Location 1 A Description 1 B Component Locations 2 3 Component Description 3 4 Operation 12 MAINTENANCE PRACTICES 1 Safety 201 SERVICE 1 General 301 2 Servicing 301 3 System Evacuation and Charging 302 4 Refrigerant Oil 306 REMOVAL/INSTALLATION 1 General 401 2 Special Tools and Equipment 401 3 General Information 402 4 Preparation 403 5 Removals 406 6 Installation 416 ADJUSTMENT/TEST 1 General 501 2 Leak Test Refrigerant 501 3 Pressure and Performance Diagnosis 504 INSPECTION/REPAIRS 601 A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 1 Issue 3 21-50-00 AIR CONDITIONING SYSTEM– DESCRIPTION/OPERATION 1. General The Vapor Cycle System (VCS) air-conditioning system provides the pilot and passengers comfort while the aircraft is on the ground, taxiing or in flight. 2. System Description and Location A Description The VCS (Vapor Cycle System) air conditioning system consists of an engine driven compressor, a condenser with fans, a receiver-dryer with Trinary pressure switch and an evaporator with an expansion valve and evaporator coil temperature sensor. Barrier hoses connect the components. EVAPORATOR ASSY HOSE ASSY BULKHEAD FITTING (INCL. W/ HOSE ASSY) COMPRESSOR ASSY HOSE ASSY HOSE ASSY BULKHEAD FITTING (INCL. W/ HOSE ASSY) HOSE ASSY HOSE ASSY RECEIVER/ DRYER ASSY HOSE ASSY HOSE ASSY CONDENSER/FAN ASSY HOSE ASSY VCS Schematic A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 2 Issue 4 21-50-00 B Component Locations The following picture illustrates the general locations of the air conditioning components. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 3 Issue 3 21-50-00 3. Component Description A. Compressor The compressor is installed on the engine and has three jobs. The first is to circulate the refrigerant through the system. The second is to remove low-pressure vapor from the evaporator. The third function is to compress low-pressure vapor to a high-pressure, high temperature vapor. The air conditioning utilizes a swash or wobble-plate-type axial compressor. The displacement of the compressor is 147cm 3 . The compressor cycles to regulate cabin temperature and to avoid evaporator coil freeze-up. The VCS compressor is engaged by a 28VDC magnetic clutch driven by a V-Belt off the back of the engine via the accessory drive. The magnetic clutch is switched off during air conditioning operation anytime the refrigerant system pressure drops below approximately 29 psi (2 bar) or rises above approximately 397 psi (27 bar) at the Trinary switch, mounted on the Receiver/Dryer assembly. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 4 Issue 4 21-50-00 B. Condenser The condenser receives high-temperature, high-pressure vapor from the compressor. The assembly is located in the empennage, behind the evaporator blower. Cooling air for the condenser enters the empennage on the pilot’s side of the aircraft through two louvered openings below the horizontal stabilizer. Air from the condenser exits the aircraft on the co-pilot’s side through a single louvered opening on the side of the empennage, forward of the horizontal stabilizer. The vapor enters at the upper fitting of the condenser. As the vapor flows through the condenser, it releases heat to the cooler ambient air flowing over the condenser. Giving up its heat causes the vapor to change to a liquid. Under average load, two- thirds of the condenser contains refrigerant vapor and the other one-third contains liquid refrigerant. The liquid refrigerant in the condenser has lost much of its heat, but sill remains at a relatively high temperature and pressure. The condenser fan is activated, as required, by the Trinary switch, located on the Receiver/Dryer Assembly. During system operation, the Trinary switch turns the condenser fans on once the refrigerant pressure rises to approximately 235 psi (16 bar) and turns the fans off when the refrigerant pressure decreases below approximately 190 psi (13 bar). A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 5 Issue 3 21-50-00 C. Receiver/Dryer with Trinary Switch The Receiver/Dryer acts as a storage and filter unit for refrigerant and oil and is located adjacent to the evaporator module in the empennage of the aircraft. The Trinary switch serves two functions. One portion of the switch cycles the condenser fans once the refrigerant pressure reaches approximately 235 psi (16 bar) and turns off the fans at approximately 190 psi (13 bar). The other portion of the switch protects the system from damage due to low refrigerant or excessive pressures by turning off the compressor. Power to the compressor is interrupted once the refrigerant pressure drops below approximately 29 psi (2 bar) or exceeds approximately 397 psi (27 bar) at the Trinary switch. The Trinary switch automatically resets once pressures are restored to a safe level. The Trinary Switch is considered an LRU (Line Replaceable Unit) which allows it to be replaced independently of the receiver/dryer assembly. The switch is sealed with an o-ring on the receiver/dryer and releases a Schrader valve upon removal thus allowing replacement without evacuating the refrigeration system. The tightening torque for the trinary switch is 7 Ft-lbs. D. Expansion Valve The expansion valve provides a regulated restriction and thus a pressure drop for the liquid refrigerant. It is located at the inlet to the evaporator module. It is the connection point between the high-pressure and low-pressure side of the refrigeration system. The expansion valve determines the flow rate of the refrigerant and provides a pressure drop, reducing pressure on the liquid refrigerant before it enters the evaporator. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 6 Issue 3 21-50-00 E. Evaporator and Blower The low temperature, low pressure liquid refrigerant is vaporized in the evaporator. Heat and moisture from the aircraft are removed and it provides low temperature, low pressure gas to the compressor. Blower Module Evaporator Module The evaporator and blower modules are connected through a flexible duct and form the evaporator assembly. This assembly removes heat and moisture from air entering the aircraft cabin. The unit is located in the empennage, aft of the aft cabin bulkhead. The evaporator module utilizes a plate and fin type evaporator coil. The plates are hydraulically expanded into the fins to ensure good thermal conductivity. The coil assembly is then coated to help prevent microbe growth and associated unpleasant odors. Replacement evaporator and blower modules from the Parts Department will be shipped as an assembly with all applicable components such as the coil, housing, blower, coil temperature sensor and expansion valve as one unit. Low-pressure liquid refrigerant from the expansion valve enters the evaporator. Because of the reduced pressure, the refrigerant boils into a vapor. The boiling refrigerant absorbs the heat from the incoming air as it changes from a liquid to a vapor. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 7 Issue 3 21-50-00 F. Cabin Temperature Sensor The sensor assembly is located in the center pedestal, between the pilot and co-pilot foot wells and is controlled by the ACCS ECU. Cabin temperature is determined by comparing the inside temperature of the aircraft with the desired cabin temperature setting. The temperature is regulated by cycling the compressor and regulating the evaporator blower speed during cooling requirements and by regulating the heater temperature actuator (ECS mixing box) during heating requirements. The temperature sensor assembly contains a calibrated thermistor and fan used to draw cabin air over the thermistor. If the sensor fails a fault will be noted in the ACCS and manual temperature control will be required by pilot input into the Control Head. G. Outside Air Temperature Sensor The outside air temperature sensor is located in the engine compartment on the engine cooling baffling, forward of the front cylinder on the co-pilot’s side of the aircraft. This temperature sensor continuously measures the temperature of the air entering the engine compartment. The ECU uses the signal from this sensor to calculate the temperature for the Outside Air Temperature (OAT) indication on the digital Control Head display. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 8 Issue 3 21-50-00 H. Defog Valve Actuator The Defog Valve Actuator Assembly located with the Heater Temperature actuator and is mounted on the co-pilot’s side of the aircraft, below the cockpit main door, behind the cabin side panel. During heater operation the air distribution system normally distributes air to the floor vents at a volume of approximately 95% with the remaining 5% distributed to the windscreen defog outlets. When the Defog mode is selected the defog actuator operates the existing defog cable and valve, and distributes nearly 100% of the air to the windscreen defog outlets. The valve operates in either a “full on” or “full off” position. I. Heater Temperature Actuator Heated air temperature in the cabin is adjusted via the “Heater Temperature Actuator”. It is located with the Defog Valve Actuator on the co-pilot’s side of the aircraft, below the cockpit main door, behind the cabin side panel. Its adjusting range extends from “heating final stop” (all air channeled from the heat exchanger) to cooling “final stop (no air channeled from the heat exchanger)”. The potentiometer reports the position of the actuator to the ACCS ECU as a feedback value. The Heater Temperature Actuator is activated by the ECU according to the temperature selected on the ACCS Control Head. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 9 Issue 3 21-50-00 J. Aft Cabin Heater Temperature Actuator Heated air temperature in the aft cabin is adjusted via the “Heater Temperature Actuator”. It’s located inside the cabin on the firewall, just above the existing aft heater valve. During cockpit heating operation, the heating airflow distributed to the aft cabin is adjusted via a rocker switch located on the ceiling console above the 2 nd row of seats. A visual LED indicator adjacent to the switch displays the position of the heater temperature actuator. Its adjusting range extends from “aft heating fully open” (maximum aft cabin heating air channeled to the aft cabin) to cooling “final stop (no air channeled to the aft cabin)”. The potentiometer reports the position of the actuator to the LED position indicator as a feedback value. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 10 Issue 3 21-50-00 K. Electronic Control Unit (ECU) The Electronic Control Unit (ECU) is located in the center pedestal between the pilot and co-pilot’s legs for all models EXCEPT for the G36 Bonanza. In the G36 Bonanza the ECU is located behind the right hand sidewall of the aircraft, just outboard of the co-pilot’s rudder pedals. ECU receives signals from the ACCS Control Head and supplies outputs accordingly. The ECU is the actual control unit of the system. All of the system’s electronic circuitry is incorporated in this unit and digital processing logic is used. The ECU also contains the blower control unit which regulates the evaporator and heater blower speeds. There are 11 blower speeds provided by this control through the use of pulse width modulation circuitry. ECU location in the G36 A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 11 Issue 3 21-50-00 L. Control Head The Control Head receives inputs from the pilot and the Automatic Climate Control System (ACCS) components. It is considered the pilot’s interface for the entire ACCS. Fault codes are displayed on the LED screen for troubleshooting. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 12 Issue 4 21-50-00 4. Operation A Terms and Definitions ACCS Automatic Climate Control System AUTO Automatic mode “on” when indicator light is illuminated Defog mode “on” when indicator light is illuminated Air Conditioning mode “on” when indicator light is illuminated ECS Environmental Control System-Heater/Ventilation System ECU Electronic Control Unit OAT Outside Air Temperature R-134a Refrigerant, CFC-Free- used in the VCS VCS Vapor Cycle System-A sealed mechanical refrigeration (air- conditioning) system used to lower the temperature of the air in an aircraft cabin. B Operation 1 Air Conditioning When air conditioned air is required, the evaporator blower is actuated and air is distributed through the overhead ceiling console vents. For maximum cooling the firewall air shut off valve should be closed. 2 Heat When heat is required, the ACCS shuts off the compressor, switches the evaporator blower to a low setting (not user selectable) and regulates the heater/defog volume and temperature in the forward cabin. Heated air is also directed to the aft cabin according to the position of the Aft Cabin Heater Temperature Actuator. During heater operation, heated air is distributed approximately 95% to the floor ducts with the remaining air being diverted to the windscreen defog ducts. Note that the firewall air shut off valve must be open for heat/defog operation. 3 Defog When the Defog “ ” mode is selected maximum defog air is distributed to the windscreen. Temperature selection on the Control Head regulates the temperature of the defog air. Note that the temperature of the defog air can only be reduced to ambient levels since the air conditioning is not active during the heat or defog modes. Note that the firewall air shut off valve must be open for heat/defog operation. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 13 Issue 3 21-50-00 4 Automatic Climate Control System (ACCS) The Automatic Climate Control System (ACCS) for the Beech Bonanza is a fully automatic system with manual operation capabilities The pilot may choose between manual operation and fully automatic operation where only the desired temperature need be selected. In manual or automatic operation, the system offers 11 choices for the air conditioning blower speed by utilizing pulse width modulation control circuitry. The Climate Control System air distribution and temperature regulation is accomplished with actuators. Additionally, the heater temperature door actuator utilizes a feedback potentiometer. These actuators move the air distribution doors to the proper position according to information sent by the ECU. The switch activates the compressor mode. When the compressor mode is “On” the adjacent annunciator light is illuminated. In the “On” mode, the compressor is available if the ACCS determines that its operation is required. Pressing the switch “toggles” the compressor mode On and Off. Note: When the compressor “on” mode is activated, as indicated by the annunciator lamp adjacent to the button, it does not indicate that the compressor is operating, only that it is available for use by the ACCS if required. The ACCS has self-diagnostic capabilities which can be displayed on the screen of the Control Head. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 14 Issue 4 21-50-00 Raises cabin temperature in 1° increments. The temperature display can be switched from °C to °F (and vice versa) as follows: Press and hold the temperature “+” and “-“buttons simultaneously. Displays outside air temperature for 5 seconds. Raises fan speed in 10% increments when air conditioning is in operation. Fan Speed is indicated as a percentage, in the display, for 5 seconds after the manual selection is made. Turns Climate Control System off. Turns Climate Control System on. Resumes present mode and temperature. -Automatic Mode- All functions are controlled automatically. All previously selected manual settings are cancelled. -Defog Mode- Blower runs at maximum speed and can NOT be regulated. Maximum defog air is directed to the windshield. Pressing this button “toggles” the defog mode On and Off. Lowers cabin temperature in 1° increments. Lowers fan speed in 10% increments. Possible in modes other than defog and heat. ->Note that when a specific, manual fan speed is selected, the climate control system maintains this fan speed until a different manual fan speed is selected or the “AUTO” button is depressed, reactivating automatic fan speed control and illuminating the annunciator light adjacent to the “AUTO” button. When the “AUTO” mode is active, fan speed is automatically regulated by the climate control system, between 40% and maximum. During heating mode, air is supplied through the overhead vents at a low blower speed which is not user selectable. Turns the Compressor Mode On or Off. Pressing this button “toggles” the compressor selection mode On and Off. The compressor mode is “On” when the annunciator light adjacent to the icon is illuminated. -> Note that the annunciator light only indicates that the compressor is available for use, if required by the climate control system, not that the compressor is actually on. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 15 Issue 3 21-50-00 a) To display the Diagnostics Fault Codes, turn on the Automatic Climate Control System and depress the ON button three times in succession. The digital display on the Control Head will display any active fault codes. Repeatedly pressing the ON button will scroll through the active codes. Each code displayed should be addressed in turn until the No Faults code “E00” is displayed. Also refer to “Inspection/Repair” section for additional information. Fault Display Codes: Fault Code Information Correction E00 No Faults - E01 Cabin Temp Sensor- Shorted Check cabin temp sensor wiring and sensor for correct operation. Refer to temperature/resistance graph, section 21- 50-00, 4.B.4.e page 18. E02 Cabin Temp Sensor- Open Check cabin temp sensor wiring and sensor for correct operation. Refer to temperature/resistance graph, section 21- 50-00, 4.B.4.e page 18. E03 Evap Temp Sensor- Shorted Check evaporator coil temp sensor wiring and sensor for correct operation. Refer to temperature/resistance graph, section 21- 50-00, 4.B.4.g page 20. E04 Evap Temp Sensor-Open Check evaporator coil temp sensor wiring and sensor for correct operation. Refer to temperature/resistance graph, section 21- 50-00, 4.B.4.g page 20. E05 Not Currently Used - E06 Not Currently Used - E07 OAT Sensor-Shorted Check OAT sensor wiring and sensor for correct operation. Refer to temperature/resistance graph, section 21- 50-00, 4.B.4.f page 19. E08 OAT Sensor-Open Check OAT sensor wiring and sensor for correct operation. Refer to temperature/resistance graph, section 21- 50-00, 4.B.4.f page 19. E09 Not Currently Use - E10 Heater Blend Air Actuator-Open Check actuator sensor wiring and sensor for correct operation. E17 No Communication with ECU Check ECU wiring and system circuit breakers for correct operation. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 16 Issue 3 21-50-00 b) Advanced Diagnostics The Advanced Diagnostics display mode is activated by pressing and holding the “ON” button for five seconds while the Fault Code display is active (Refer to section 21-50-00, 4.B.4.a page 15). Press the “ON” button to cycle through the following displays: “CAb” Cabin Temperature Sensor temperature reading “EUAP” Evaporator Coil Temperature Sensor temperature reading “HEAt” ECS mixing valve position (percentage open) “A-C” VCS compressor command (ON or OFF) “FAn” Blower Speed-Evaporator or Heater/Defog (percentage of max) Press the “OFF” button to return to the normal display mode. c) Firmware Version The Firmware Version display mode is activated by pressing and holding the “ON” button for five seconds while the Advanced Diagnostics display is active (Refer to section 21-50-00, 4.B.4.b page 16). Press the “ON” button to cycle through the following displays: “ECU” ECU Module Firmware Version “CtrL” Control Head Firmware Version Press the “OFF” button to return to the normal display mode. d) Parameter-Programming Function This function is used to confirm the programming of the automatic climate control ECU prior to operational sign-off and release of the aircraft to the customer. The parameter function is activated by pressing and holding the “OFF” button for five seconds while the advanced diagnostics display mode is active. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 17 Issue 3 21-50-00 -Press the FAN “+” or the FAN “-“ buttons to select configuration (config) setting: “Pf-x” (“x” may be displayed as 0, 1 or 2 depending on setting) . -Press the TEMP “+” or the TEMP “-“ buttons to change the selected config setting to: “Pf-1”. Exit and save the settings in the programming mode by pressing the “OFF” button. CAUTION: DO NOT CHANGE ANY OTHER SETTINGS within the Parameter-Programming screen or damage to the system may occur. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 18 Issue 3 21-50-00 e) Cabin Temperature Sensor Resistance vs. Temperature Curve Resistance KΩ 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 10 20 30 40 50 60 70 80 90 100 110 120 Temperature °F CABIN TEMPERATURE SENSOR °F °C 10 -12.2 20 -6.7 30 -1.1 40 4.4 50 10.0 60 15.6 70 21.1 80 26.7 90 32.2 100 37.8 110 43.3 A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 19 Issue 3 21-50-00 f) Outside Air Temperature Sensor Resistance vs. Temperature Curve Resistance KΩ 1 3 5 7 9 11 13 15 17 19 10 10 20 30 40 50 60 70 80 90 100 110 Temperature °F OUTSIDE AIR TEMPERATURE SENSOR °F °C 10 -12.2 20 -6.7 30 -1.1 40 4.4 50 10.0 60 15.6 70 21.1 80 26.7 90 32.2 100 37.8 110 43.3 A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 20 Issue 3 21-50-00 g) Evaporator Coil Temperature Sensor Resistance vs. Temperature Curve Resistance KΩ 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 10 20 30 40 50 60 70 77 80 90 100 110 Temperature °F EVAPORATOR COIL TEMPERATURE SENSOR °F °C 10 -12.2 20 -6.7 30 -1.1 40 4.4 50 10.0 60 15.6 70 21.1 80 26.7 90 32.2 100 37.8 110 43.3 A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 201 Issue 3 21-50-00 AIR CONDITIONING SYSTEM– MAINTENANCE PRACTICES 1. Safety A The following are Warnings for working with R134a refrigerant. • Avoid breathing R-134a air-conditioner refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose, and throat. Wear eye protection when serviced the air conditioning refrigerant system. Serious eye injury can result from eye contact with refrigerant. If eye contact is made, seek medical attention immediately. • If accidental system discharge occurs, ventilate the work area before resuming service. Large amounts of R-134a refrigerant will displace oxygen and cause suffocation. Work only in well-ventilated areas. • Do not heat refrigerant containers above 125°F or expose refrigerant to open flame. Do not use open flame to heat refrigerant containers. • Do not intentionally drop, puncture or incinerate refrigerant containers. • The evaporation rate of R-134a refrigerant at average temperature and altitude is extremely high. As a result, anything that comes in contact with the refrigerant will freeze. Always protect skin or delicate objects from direct contact with refrigerant. For personal protection, goggles and protective gloves should be worn and clean cloth wrapped around fittings, valves and connections when doing work that includes opening the refrigerant system. If R-134a refrigerant comes in contact with any part of the body, severe frostbite and personal injury can result. Flush exposed zone immediately with cold water and obtain prompt medical assistance. • If R-134a refrigerant comes in contact with any part of the body, severe frostbite and personal injury can result. Flush exposed zone immediately with cold water and obtain prompt medical help. • R-134a service equipment or aircraft air conditioning system should not be pressure tested or leak tested with compressed shop air. Though R-134a is considered non-flammable, some mixtures of air and R-134a have been shown to be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion causing injury or property damage. • Never add R-134a refrigerant to a system that has not been evacuated to 29 inches of mercury vacuum pressure. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 202 Issue 3 21-50-00 B The following are Cautions for working with R134a refrigerant. • Liquid refrigerant is corrosive to metal surfaces. Follow the operating instructions supplied with equipment being used. • Never add R-12 refrigerant to an air conditioning system designed to use R- 134a. Damage to the system may result. • R-12 compressor oil cannot be mixed with the R-134a compressor oil. They are NOT compatible. • Do NOT use R-12 servicing equipment or parts on an R-134a air conditioning system. C The following are Systems Service Precautions. • Never open or loosen a connection before discharging the system refrigerant. • Do NOT open a refrigerant system or uncap a replacement component unless it is as close as possible to room temperature. This will prevent condensation from forming inside of a component which is cooler than the surrounding air. • Before disconnecting a component from the system, clean the outside of the fittings thoroughly. • Immediately after disconnecting a component from the system, seal the open fittings with a cap or plug. • Before connecting an open fitting always install a new seal or gasket designed for the specific component. Coat the fitting and seal with clean refrigerant oil before connecting. • Do NOT remove the sealing caps from a replacement component until ready to install. • When installing a refrigerant line avoid bends which produce radiuses smaller than specified below for the hose being installed. Hose Size Minimum Bend Radius 1/2” 13mm (#10) 3.0 inch 13/32 10mm (#8) 2.5 inch 5/16” 8mm (#6) 2.0 inch • Position refrigerant lines so to avoid exhaust components, flight controls, or items which may chafe the line. Refer to A.C. 43-13, Acceptable Methods, Techniques, and Practices for compliant methods of installation. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 203 Issue 5 21-50-00 • Apply a light coat of Ester RL-500S (Castrol Icematic SW100 and the Emkarate 100H are also approved) refrigerant oil to the o-rings of all fittings. Tighten all fittings to torques specified in the table below. Use an anti-torque back-up wrench on ALL component fittings. • DO NOT use Teflon® tape or thread sealants on connections or fitting threads. • Tighten fittings only to the specified torque listed below. The refrigerant fittings will not tolerate over-tightening. Tube O.D. Thread Size Torque Ft-lbs. 3/8” (.375”) 5/8-18 11-13 1/2” (.500”) 3/4-16 15-20 5/8” (.625”) 7/8-14 21-27 Trinary Switch Torque: 7 Ft-lbs. • When disconnecting a fitting use a wrench on BOTH halves of the fitting. This will prevent twisting of the refrigerant lines or tubes. • Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do NOT open an oil container until ready to use and install the cap immediately after using. Store the oil only in a clean moisture-free container. • Keep service tools and the work area clean. Contamination of the VCS air conditioning system through careless work habits must be avoided. • Plumbing systems in aircraft are subject to vibration and extreme temperature and atmospheric pressure changes. Therefore, strict adherence to procedures and correct use of material is mandatory. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 301 Issue 5 21-50-00 AIR CONDITIONING SYSTEM– SERVICE 1. General The Vapor Cycle System (VCS) air-conditioning system may require service for system evacuation and charging. Caution: Make sure the battery is connected before powering the system with an APU. Refer to applicable aircraft maintenance manual for proper connecting of the APU. 2. Servicing A Before servicing the system check the system for leaks by installing pressure gauges and charge the system to 200 psig with dry nitrogen and let the aircraft set for about 8 hours. Ensure the system maintains a minimum dry nitrogen pressure of 195 psig. B Vacuum the system for at least 45 minutes and charge it with 24 ounces (680 grams) of refrigerant meeting specification R-134a. DO NOT OVERCHARGE C Start the engine and perform a diagnostic test using the Environmental Control System Electronic Control Unit (ECU) (Refer to section 21-50-00, 4.B.4.b page 15). Using a probe thermometer, check the air temperature at each outlet. The air temperature should be approximately equal to the appropriate “air duct temperature” shown in the right column below. NOTE: Use This Reference Table as a Maximum Pressure and Temperature Chart A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 302 Issue 6 21-50-00 3. System Evacuation and Charging CAUTION: ONLY R-134a refrigerant is to be used. Other refrigerants will damage the system. Overcharging of the system will result in reduced performance, reduced service life and/or damage to the system components. Approved Refrigerant Oils: Ester RL-500S Castrol Icematic SW100 Emkarate 100H A Special Tools and Equipment The following tools and equipment is required to charge the refrigerant system. • Approved Refrigerant Oil, 4 fluid oz. (118 cc). • Charging Station/Reclaim/Recycle Cart (R-134a) ~OR~ Air-Conditioner Vacuum Pump, R-134a Manifold Gauges and Weight Scale (0 - 50 pounds). • Small Hand Tools and Socket Set • R-134a Refrigerant, at least 24 oz. by weight • Thermometer, 0 - 150°F • Inspection Mirror, Adjustable • Service Light or Flashlight • Hand Shop Towels • Electronic Refrigerant Leak Detector B Initial Refrigerant Evacuation Procedure The compressor as received from the supplier is pre-charged with air conditioner oil. 4 fluid oz. (118 cc) of approved refrigerant oil shall be added to the receiver/dryer at the time of initial installation BEFORE charging the system. WARNING Review warnings and cautions listed in MAINTENANCE PRACTICES- SAFETY section before evacuating refrigeration system. 1 Prior to charging the system with R-134a refrigerant, the 4 fluid oz. (118 cc) of approved refrigerant oil must have been added. The system must then be evacuated for a MINIMUM of 45 minutes to remove air and moisture which if not removed can damage the system or cause the system to perform incorrectly. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 303 Issue 3 21-50-00 2 Remove service port caps from aircraft system. They are located on the evaporator assembly. The service ports are accessed from inside the aircraft’s baggage compartment once the evaporator trim cover has been removed. 3 Confirm that both valves of the charging manifold are close and connect charging manifold to service ports. 4 Connect manifold charging (yellow) hose to vacuum pump. Turn ON pump. 5 Open both valves of charging manifold gauge set. 6 Open both valves of charging hose quick connect fittings. 7 Observe charging manifold gauges to verify vacuum. 8 Evacuate system for 45 minutes. Final system vacuum should be 25 to 29 inches of mercury. 9 Close charging manifold valves. Turn OFF vacuum pump. Observe the vacuum level for 5 minutes as a leak check of the refrigeration system. If vacuum is not maintained, locate and repair the refrigeration system leak before continuing. 10 Disconnect manifold service hose from vacuum pump. System is ready for refrigerant charging. NOTE: Any change in vacuum pressure, or failure to achieve a system pressure of 25 to 29 in. hg. vacuum indicates the presence of a plumbing leak. Locate and fix all leaks. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 304 Issue 3 21-50-00 B Refrigerant Charging Procedure There are various methods of charging refrigerant into the air-conditioning system. These include using refrigerant recovery/recycle unit. (Refer to the manufacturer’s instructions) Use of manifold pressure gauges, R-134a cylinder and weight scale is outlined in this section. NOTE: It is necessary to run the engine of the aircraft to finalize the complete refrigerant charge when a Charging/Reclaim/Recycle Station is NOT used. NOTE: If refrigerant Charging/Reclaim/Recycle Station is used, refer to applicable equipment manufacturer instructions for VCS servicing. 1 Verify leak-check and evacuation of the system is completed. 2 Connect yellow manifold charging hose to R-134a cylinder. Open valve. 3 Very slightly open charge hose fitting at manifold gauge set and vent air from hose until refrigerant is evidently escaping. 4 Place refrigerant bottle on 0 - 50 pound (0-25 kg) scale. Record weight. 5 Open both manifold gauge set valves. Add refrigerant to system until pressures stabilize. 6 Close manifold valves and verify system pressure is 50 psig (3.4 bar) or greater. NOTE: System’s pressure must be above 50 psig (3.4 bar) to close low pressure cutoff switch. Otherwise compressor will not turn ON. 7 If necessary, warm the refrigerant bottle by immersion in warm water. WARNING Do not use open flame to warm refrigerant bottle. Do not heat bottle above 125 °F (51°C). 8 Move aircraft to run-up area. 9 Start aircraft engine. Select “AUTO” on Automatic Climate Control head and set the temperature to ”55°F (13°C)”. Idle aircraft engine at 1200 - 1800 RPM. WARNING Do NOT open high pressure (RED) valve on manifold gauge set. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 305 Issue 3 21-50-00 10 With system operating, observe the system discharge and suction pressures. 11 With the R-134a cylinder connected to the charging hose, charging container shutoff valve open and hose purged of air, slowly open the suction (BLUE) manifold valve. The suction pressure will increase to 60 - 70 psig (4.1 - 4.8 bar). NOTE: As refrigerant enters the compressor a slight increase in compressor discharge pressure will be noticed. 12 Continue to add refrigerant until 24oz. (680 grams) of refrigerant have been added. DO NOT OVERCHARGE 13 Close suction manifold valve (BLUE) and let system operate for 5 to 10 minutes to evaluate performance. NOTE: Letting the system stabilize is required since the expansion valve is trying to stabilize the system pressure. NOTE: System charge is 24 ounces (680 grams) of R-134a. 14 With the system fully charged and operating, observe the suction and discharge pressures. Typical values at various ambient temperatures, with hot cabins, are shown bellow. NOTE: The pressure values listed in this document vary according to environmental factors and are to be used as a guideline for further troubleshooting, not as a sole source. Ambient Temperature 21°C (70°F) 27°C (80°F) 32°C (90°F) 38°C (100°F) 43°C (110°F) Air Temperature At Evaporator Outlet 7-9°C (45-48°F) 8-13°C (46-55°F) 11-16°C (52-61°F) 14-20°C (57-68°F) 17-25°C (63-77°F) Low Side Service Port Pressure (psi) 18 30 20 35 22 39 25 43 26 47 High Side Service Port Pressure (psi) 150 220 160 235 220 310 250 320 280 340 15 Allow system to operate for 10 minutes then shutdown. NOTE: After shutdown, both suction and discharge pressures will begin to equalize. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 306 Issue 6 21-50-00 16 Close refrigerant container shutoff valve. Record the refrigerant container final weight and calculate system refrigerant charge. CHARGE (lb.) = W initial (lb.) - W final (lb.) 17 Turn knob on suction and discharge charging hose quick coupler to closed position and disconnect hoses from service ports. 18 Remove yellow charging hose from refrigerant container and store manifold gauge set. 19 Install service caps on fittings of air conditioning system. 4. Refrigerant Oil Approved Refrigerant Oils: Ester RL-500S Castrol Icematic SW100 Emkarate 100H It is important to have the correct amount of oil in the air conditioning system. This will ensure proper lubrication of the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the system. The oil used in the compressor is a synthetic ester oil: Ester RL-500S. This is a wax-free refrigerant oil. Only approved refrigerant oils are to be used. DO NOT use any other type of refrigerant oil! The oil container should be kept tightly capped until it is ready for use and then immediately capped after use to prevent contamination. Refrigerant oil will quickly absorb any moisture it comes in contact with. It will not be necessary to check the oil level in the compressor or to add oil unless there has been an oil loss. This may be due to a rupture or leak from a line, o-ring, shaft seal, evaporator, or condenser, etc. Oil loss at a leak point will be evident by the presence of a wet shiny surface around the leak. Oil Level When an air conditioning system is assembled at the factory all components except the compressor are refrigerant oil free. After the system has been charged and operated, the oil in the compressor is dispersed through the system. The evaporator, condenser, receiver-dryer, and compressor will retain a significant amount of oil. When a component is replaced, the specified amount of refrigerant oil must be added. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 307 Issue 6 21-50-00 Compressor Replacement Considerations: 1. If the compressor is inoperative and the system still has refrigerant pressure, recover the refrigerant with an approved refrigerant recovery machine. Record amount of oil collected. Remove compressor and drain oil into measuring cup. Examine oil, if the compressor failed and locked-up right away, then oil will likely appear generally clean with perhaps some small metal particles. In this case refer to Seamech instructions for flushing the vapor cycle system. The receiver drier generally collects any other debris. If, however, the oil appears black or dirty, then all the system components should be flushed or replaced according to Seamech instructions for flushing the vapor cycle system. 2. If the VCS was judged to be acceptably clean, then drain the new compressor and add fresh refrigerant oil, from the approved list of refrigerant oils, in the amount drained from old compressor or 3.5 fluid oz. (104 cc), whichever is greater, plus the amount collected in recovery machine. 3. If the VCS was flushed and all components except for the hoses are being replaced, the replacement refrigerant compressor will be provided with the correct amount of oil for the compressor. 4 fluid oz. (118 cc) of fresh refrigerant oil, from the approved list of refrigerant oils, will need to be added to the inlet fitting of the replacement (new) receiver/dryer upon installation. No additional oil will need to be added. Adding oil when component is replaced (when reusing same compressor): This is often one of the most difficult decisions faced by the service technician. Too much oil in a system will degrade the performance of the VCS, but a system without enough oil is likely to experience a premature compressor failure. When refrigerant or a major VCS component is replaced, refrigerant oil shall be added to compensate for the amount of oil in the part which is being replaced. During the recovery and removal of R-134a refrigerant from the vapor cycle system, oil in mixture is also removed. Refer to the specific refrigerant recovery machine instructions regarding oil collection. The oil collected and then drained from the refrigerant recovery machine generally foams up as the refrigerant in solution is exposed to atmospheric pressure. It is important to allow time for correct and accurate measurement of the refrigerant oil removed refrigerant recovery. NOTE Have the new component and o-rings ready for installation before opening the refrigerant system in order to limit the time that the system is open to the atmosphere. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 308 Issue 6 21-50-00 Refrigerant Recovery and Recharge Determine the amount of oil recovered during the refrigerant recovery process and add the same amount of new refrigerant oil back into the VCS component being replaced. Refrigerant Hose Determine the amount of oil recovered during the refrigerant recovery process and add the same amount of new refrigerant oil back into the VCS. This oil is to be added into the refrigeration hose once the lower end of the hose has been attached and secured. Expansion Valve Determine the amount of oil recovered during the refrigerant recovery process and add the same amount of new refrigerant oil back into the VCS. This oil is to be added into the refrigeration hose attached to the expansion valve on the evaporator coil. Evaporator Coil Determine the amount of oil recovered during the refrigerant recovery process and add the same amount of new refrigerant oil back into the VCS, plus an additional 1 fluid oz. (29 cc). This oil is to be added into the refrigeration hose attached to the expansion valve on the evaporator coil. Condenser Coil Determine the amount of oil recovered during the refrigerant recovery process and add the same amount of new refrigerant oil back into the VCS, plus an additional 2 fluid oz. (58 cc). This oil is to be added into the refrigeration fitting port on the condenser once the lower hose to the condenser has been attached and secured. Receiver/Dryer Determine the amount of oil recovered during the refrigerant recovery process and add the same amount of new refrigerant oil back into the VCS, plus an additional 0.5 fluid oz. (15 cc). This oil may be added into either refrigeration fitting port on the receiver/dryer. Trinary Switch The Trinary Switch can be removed without recovering or discharging the refrigerant from the VCS since it is isolated from the Receiver/Dryer with a Schrader valve. No refrigerant oil needs to be added to the VCS during the replacement of the Trinary Switch. Compressor Refer to Compressor Replacement Considerations, above. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 401 Issue 6 21-50-00 AIR CONDITIONING SYSTEM– REMOVAL/INSTALLATION 1. General The following provides removal and installation procedures for the Vapor Cycle System (VCS) air-conditioning system. 2. Special Tools and Equipment The following tools and equipment are required or recommended • Small hand tools and socket set • Burroughs tool No. BT-33-73F (or equivalent) belt tension gauge (recommended) • Torque wrench capable of reading In.-Lbs. or Nm. • Approved Refrigerant Oil, 2 fluid oz. (58 cc). • Charging Station/Reclaim/Recycle Cart (R-134a) ~OR~ Air-Conditioner Vacuum Pump, R-134a Manifold Gauges and Weight Scale (0 - 50 pounds). • Small Hand Tools and Socket Set • R-134a Refrigerant, at least 24 oz. by weight • Thermometer, 0 - 150°F • Inspection Mirror, Adjustable • Service Light or Flashlight • Hand Shop Towels • Electronic Refrigerant Leak Detector A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 402 Issue 3 21-50-00 3. General Information A Component Access Access to the air conditioning system can be accomplished through the engine cowl, behind the baggage compartment and the evaporator trim cover located against the aft, lower bulkhead of the baggage compartment. B Belt Tensioning Belt Part Number: Continental Motors drive belt PN 653003-1. Refer to 21-50-00, section 6.A.5, page 412 for belt tension instructions. WARNING: Do NOT over tighten belt. After approximately 5 hours of initial operation, recheck belt tension and adjust as required to maintain 50-70 pound belt tension. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 403 Issue 4 21-50-00 4. Preparation A. The following are Warnings for working with R-134a refrigerant. • Avoid breathing R-134a air-conditioning refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Wear eye protection when servicing the air conditioning refrigerant system. Serious eye injury can result from eye contact with refrigerant. If eye contact is made, seek medical attention immediately. • If accidental system discharge occurs, ventilate the work area before resuming service. Large amounts of R-134a refrigerant will displace oxygen and cause suffocation. Work only in well-ventilated areas. • Do not heat refrigerant containers above 125°F or expose refrigerant to open flame. Do not use open flame to heat refrigerant containers. • Do not intentionally drop, puncture or incinerate refrigerant containers. • The evaporation rate of R-134a refrigerant at average temperature and altitude is extremely high. As a result, anything that comes into contact with the refrigerant will freeze. Always protect skin or delicate objects from direct contact with refrigerant. For personal protection, goggles and protective gloves should be worn and clean cloth wrapped around fittings, valves and connections when doing work that includes opening the refrigerant system. • If R-134a refrigerant comes in contact with any part of the body, severe frostbite and personal injury can result. Flush exposed zone immediately with cold water and obtain prompt medical assistance. • R-134a service equipment or aircraft air conditioning system should not be pressure tested or leak tested with compressed shop air. Though R-134a is considered non-flammable, some mixtures of air and R-134a have been shown to be combustible at elevated pressures. These mixtures are potentially dangerous and may result in fire or explosion, causing injury or property damage. ƒ Never add R-134a refrigerant to a system that has not been evacuated to 29 inches of mercury vacuum pressure for the period of time specified within the service instructions. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 404 Issue 4 21-50-00 B The following are Cautions for working with R-134a refrigerant. • Liquid refrigerant is corrosive to metal surfaces. Follow the operating instructions supplied with equipment being used. • Never add R-12 refrigerant to an air conditioning system designed to use R-134a. Damage to the system may result. • R-12 compressor oil cannot be mixed with the R-134a compressor oil. They are NOT compatible. • Do NOT use R-12 servicing equipment or parts on an R-134a air conditioning system. C The following ar Systems Service Precautions • Never open or loosen a connection before discharging the system refrigerant. • Do NOT open a refrigerant system or uncap a replacement component unless it is as close as possible to ambient temperature. This will prevent condensation from forming inside of a competent which is cooler than the surrounding air. • Before disconnecting a component from the system, clean the outside of the fittings thoroughly. • Immediately after disconnecting a component from the system, seal the open fittings with a cap or plug. • Before connecting an open fitting, always install a new seal, o-ring or gasket designed for the specific component. Coat the fitting and seal with clean refrigerant oil, from the approved refrigerant oil list in this document, before connecting. • Do NOT remove the sealing caps from a replacement component until ready to install. • When installing a refrigerant line, avoid bends which produce radiuses smaller than specified, in the table below, for the hose being installed. ƒ Position refrigerant lines/hoses so to avoid exhaust components, flight controls or items which may chafe the lines/hoses. Refer to A.C. 43-13, Acceptable Methods, Techniques and Practices for compliant methods of installation. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 405 Issue 4 21-50-00 • Apply a light coat of clean refrigerant oil, from the approved refrigerant oil list in this document, to the o-rings of all fittings. Tighten all fittings to torque values specified in the table, below. Use an anti-torque back-up wrench on ALL component fittings. • Do NOT use Teflon® tape or thread sealants on connections or fitting threads. • Tighten fittings only to the specified torque listed below. The refrigerant fittings will not tolerate over-tightening. Trinary Switch Torque: 7 Lb-Ft. • When disconnecting a fitting, use a wrench on BOTH halves of the fitting. This will prevent twisting of the refrigerant lines or tubes. • Refrigerant oil will absorb moisture from the atmosphere if left uncapped. Do NOT open an oil container until ready to use and install the cap immediately after using. Store the oil only in a clean moisture-free container. • Keep service tools and the work area clean. Contamination of the VCS air conditioning system through careless work habits must be avoided. • Plumbing systems in aircraft are subject to vibration and extreme temperature and atmospheric pressure changes. Therefore, strict adherence to procedures and correct use of material is mandatory. D The following are Aircraft Service Precautions. • Secure the aircraft with a tail stand. • Disconnect the aircraft battery. Pull all four (4) air conditioning circuit breakers. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 406 Issue 3 21-50-00 5. Removals A Compressor (see Figure 1) 1 Open Engine Cowl to gain access to the Compressor. 2 Remove tie wraps around wire sleeve at clutch. Pull back sleeve to gain access to connector. Disconnect electrical connector from compressor clutch. 3 Evacuate refrigerant from system (see “SERVICE” section). 4 Loosen and disconnect refrigerant plumbing to compressor. Cap all open lines and ports. 5 Loosen and remove nuts securing Compressor to engine. Retain hardware for re- use. 6 Disconnect and remove drive belt. 7 Remove Compressor Figure 1 “Compressor Installation” A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 407 Issue 3 21-50-00 B Outside Air Temperature (OAT) Sensor (see Figure 2) 1 Open Engine Cowl to gain access to the OAT Sensor. 2 Locate sensor in the right, front baffling. 3 Disconnect wiring to OAT Sensor. 4 Remove Snap Ring, Washers and Gaskets securing OAT Sensor. Retain hardware for re-use. 5 Remove OAT Sensor. Figure 2 “OAT Sensor Installation” A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 408 Issue 3 21-50-00 C Condenser (see Figure 3) 1 Open lower section of aft cabin bulkhead gain access to the Condenser. 2. Recover refrigerant from air conditioning system. 3 Locate Condenser. 4 Disconnect wiring to Condenser. 5 Loosen and remove condenser mounting hardware (Bolts and Washers) from the bottom and top of condenser. Retain hardware for re-use. 6 Disconnect 8” Flex Duct to Condenser and Plenum. 7 Disconnect hoses to Condenser. Cap all open lines and ports. 8 Remove Condenser. CONDENSER/FAN ASSY UPPER CONDENSER MOUNTING HARDWARE LOWER CONDENSER MOUNTING HARDWARE Figure 3 “Condenser/Fan Installation” A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 409 Issue 3 21-50-00 D Blower Assembly (see Figure 4) 1 Remove interior panels to gain access to the Blower Assembly. 2 Locate Blower Assembly. 3 Disconnect wiring to Blower Assembly. 4 Disconnect 10” Flex Duct to Blower and Evaporator. 6 Loosen and remove clamps securing 3” fresh air hose and the two (2) 3” flex hoses from the Blower Assembly. Retain clamps for re-use. 7 Disconnect 3” fresh air hose and the two (2) 3” flex hoses from the Blower Assembly. 8 loosen and remove screws (8) securing Blower Assembly. Retain hardware fro re-use. 9 Lower and remove the Blower Assembly down from the overhead duct. Figure 4 “Blower Installation” A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 410 Issue 3 21-50-00 E Evaporator (see Figure 5) 1 Remove baggage panels to gain access to the Evaporator. 2 Locate Evaporator. 3 Disconnect refrigerant plumbing to Evaporator. Cap all open lines and ports. 4 Loosen and remove screws securing Evaporator. Retain hardware for re-use. 5 Remove Evaporator. Figure 5 “Evaporator” A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 411 Issue 4 21-50-00 F Receiver/Dryer (see Figure 6) 1 Remove Baggage Panels to gain access to the Receiver/Dryer. 2 Locate Receiver/Dryer. 3 Disconnect wiring to Receiver/Dryer Trinary Switch. a. To replace only the Trinary switch, there is no need to recover the refrigerant since a check valve prevents refrigerant loss when the Trinary switch is removed. (1) Loosen and remove Trinary Switch. (2) Install replacement Trinary Switch with new o-ring and torque to 7 Lb-Ft. 4 Recover refrigerant from air conditioning system, but do NOT pull a vacuum on the system (see “SERVICE” section). 5 Disconnect refrigerant hoses to Receiver/Dryer. Cap all open lines and ports. 6 Loosen and remove hardware securing Receiver/Dryer to aircraft. Retain hardware for re-use. 7 Remove Receiver/Dryer. Figure 6 “Receiver/Dryer Installation” A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 412 Issue 3 21-50-00 G Heater/Defog Drive Actuators (see Figure 7) 1 Locate the Heater Drive Actuator behind the co-pilot side panel, below the cockpit entry door. 2 Disconnect wiring to Heater Drive Actuator. 3 Loosen and remove Screws, Washers and Nuts securing Heater Drive Actuator. Retain hardware for re-use. 4 Remove Heater Drive Actuator. 5 Repeat for other location. Figure 7 “Heater Drive Actuator” A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 413 Issue 5 21-50-00 H Electronic Control Unit (ECU) (see Figures 8 and 8a) All EXCEPT G36 Bonanza (see Figure 8) 1 Locate the ECU at the lower centerline of the cockpit console. 2 Disconnect wiring connectors to ECU. 3 Loosen and remove Screws (6) securing ECU. Retain hardware for re-use. 4 Remove ECU. Figure 8 “Electronic Control Unit (ECU) Installation-All EXCEPT G36” G36 Bonanza (see Figure 8a) 1 Locate the ECU behind the right hand sidewall of the aircraft, just outboard of the co-pilot’s rudder pedals. 2 Disconnect wiring connectors to ECU. 3 Gently work ECU loose from Dual Lock fastener tape from sidewall of aircraft. 4 Remove ECU. Figure 8a “Electronic Control Unit (ECU) Installation in the G36 Bonanza” ECU on the G36 A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 414 Issue 3 21-50-00 I Aft Cabin Heat Switch and Indicator (see Figure 9) 1 Locate the Rear Heat Switch and Indicator in the ceiling. 2 Loosen and remove Screws holding mounting plate for Switch and Indicator. Retain hardware for re-use. 3 Loosen and remove Screws, Washers and Nuts securing Switch and/or Indicator to mounting plate. Retain hardware for re-use. 4 Pull Rear Heat Switch and/or Indicator out to gain access and disconnect wiring as required. 5 Remove Rear Heat Switch and/or Indicator, as required. Figure 9 “Rear Heat Control Module Installation” A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 415 Issue 3 21-50-00 J Cabin Temperature Sensor (see Figure 10) 1 Locate the Cabin Temperature Grille in center pedestal between pilot and co-pilot foot wells. 2 Loosen and remove Screws securing either one of the center pedestal side panels and remove panel. Retain hardware for re-use. 3 Disconnect wiring connectors to Cabin Temperature Sensor. 4 Loosen and remove (4) Screws securing the Cabin Temp Sensor and remove Cabin Temp sensor, spacer and grille. Retain hardware, spacer and grille for re- use. Figure 10 “Cabin Temperature Sensor” A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 416 Issue 3 21-50-00 6. Installation A Compressor (see Figure 1) 1 Open Engine Cowl to gain access to the Engine. 2 When the compressor is replaced, drain and measure all the oil from the old compressor. Drain and discard all of the oil from the new compressor. Add back into the new compressor the same amount of new oil that was drained out of the old compressor. 3 Position Compressor on compressor mount pad. 4 Install nuts to secure Compressor to the engine. Torque 160-190 In-Lb. 5 Install drive belt. 6 Tension Belt as follows: a) Loosen the jam nut on the adjusting bolt and the idler pulley slide nut. The idler pulley slide nut should be loosened only enough to allow the slide to move freely. The adjusting bolt should be turned out far enough to allow installation of the belt. b) Install the belt. c) Slide the idler pulley snugly against the belt and tighten the adjusting bolt finger tight into its socket. The idler pulley should be rotatable by hand under the belt. d) Tighten the adjusting bolt two full turns. Secure the adjusting bolt jam nut (275- 325 in-lbs) and the idler pulley slide nut (300-350 in-lbs). e) Confirm that the belt tension is 50-70 lbs. by one of the following methods: 1) Use a direct reading belt tension gage such as Burroughs Tool No. BT-33- 73F 2) Measure belt deflection under a five pound load at the center of the longest belt span. Correct deflection is .3-.4 inches. f) If the belt tension is not within the above tolerance, loosen the adjusting screw jam nut and the idler pulley slide nut and readjust the tension. One full turn of the adjusting screw is about a ten pound change in the belt tension. WARNING: Do NOT over tighten belt. After approximately 5 hours of initial operation, recheck belt tension and adjust as required to maintain 50-70 pound belt tension. 7 Connect refrigerant plumbing to Compressor. 8 Re-connect wiring connector to Compressor. Slide sleeve back into original position and tie wrap in place. 9 Add refrigerant and charge system (see “SERVICE” section). 10 Leak test system (see “Adjustment/Test” section). 11 Perform diagnostic testing (refer to section 21-50-00, page 301, section 2.C and using the Environmental Control Unit (ECU) advanced diagnostics (refer to section 21-50-00, page 16, section 4.B.4.b). Note: For refrigerant pressure and performance check, refer to section 21-50-00, page 504, section 3. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 417 Issue 4 21-50-00 B Outside Air Temperature (OAT) Sensor (see Figure 2) 1 Open Engine Cowl to gain access to the OAT Sensor mount position. 2 Position sensor in the right, front baffling. 3 Install Snap Ring, Washers and Gaskets securing OAT Sensor. 4 Re-connect wiring to OAT Sensor. 5 Check system operation and fault codes (see “Description/Operation” section 21- 50-00, section 4, pages 12-20). C Condenser (see Figure 3) 1 Position Condenser in mount position. 2 Install 2 of AN3-4A bolts with AN960-10 (or NAS1149F0363P) washers in the top of the condenser assembly and 4 of AN3-4A bolts with AN960-10 (or NAS1149F0363P) washers on the bottom of the condenser assembly to secure the assembly to the upper and lower condenser mounts. 3 Re-connect refrigeration hoses with new o-rings and torque: #6 hose (lower connection): 11-13 Lb-Ft. #8 hose (upper connection): 15-20 Lb-Ft. NOTE: Always use a backup wrench when torquing fittings 4 Re-connect 8” Flex Duct to Condenser and Plenum and secure with Hose Clamps. 5 Re-connect wiring to Condenser. 6 Service the refrigeration system by leak checking the system with dry nitrogen, evacuating and recharging with 24 ounces (680 grams) of R-134a refrigerant (see “SERVICE” section). 7 Final system leak test (see “Adjustment/Test” section). 8 Close and secure all panels that were removed to gain access. 9 Check system operation and fault codes (see “Description/Operation” section 21- 50-00, section 4, pages 12-20). A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 418 Issue 6 21-50-00 D Blower Assembly (see Figure 4) 1 Position and install the Blower Assembly up to the overhead duct. 2 Install 3 of AN3-4A bolts with NAS1149F0363P washers on each side of the top of the Blower Assembly and secure Blower Assembly to upper mounting brackets. 3 Re-connect 10” Flex Duct to Blower and Evaporator and secure with Hose Clamps. 4 Re-connect wiring to Blower Assembly. 5 Close and secure all panels that were removed to gain access 6 Check system operation and fault codes (see “Description/Operation” section 21- 50-00, section 4, pages 12-20). E Evaporator (see Figure 5) 1 Position and install Evaporator. 2 Install and tighten 4 of AN3-4A bolts with NAS1149F0332P washers securing Evaporator. 3 Re-connect refrigerant hoses to Evaporator and torque: #6 hose (small hose): 11-13 Lb-Ft. #10 (large hose) hose: 21-27 Lb-Ft. NOTE: Always use a backup wrench when torquing fittings. 4 Add refrigerant and charge system (see “SERVICE” section). 5 Final system leak test (see “Adjustment/Test” section). 6 Close and secure baggage panels that were removed. 7 Check system operation and fault codes (see “Description/Operation” section 21- 50-00, section 4, pages 12-20). F Receiver/Dryer and Trinary Switch (see Figure 6) 1 Trinary Switch (a) Position and install Trinary Switch onto Receiver/Dryer with new o-ring and torque to 7 Lb-Ft. NOTE: Always use a backup wrench when torquing. (b) Reconnect wiring to Trinary Switch on Receiver/Dryer. (c) Final system leak test (see “Adjustment/Test” section). (d) Close and secure baggage panels that were removed. (e) Check system operation and fault codes (see “Description/Operation” section 21-50-00, section 4, pages 14-22). 2 Receiver/Dryer Assembly (a) Position and install Receiver/Dryer. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 419 Issue 6 21-50-00 (b) Install 2 of AN3-4A bolts with NAS1149F0363P washers through Receiver/ Dryer and mounting bracket. Tighten hardware securing Receiver/ Dryer. (c) Re-connect refrigerant hoses to Receiver/Dryer using new o-rings and torque: #6 hose: 11-13 Lb-Ft. NOTE: Always use a backup wrench when torquing fittings. (d) Re-connect wiring to Trinary Switch on Receiver/Dryer. (e) Service the refrigeration system by leak checking the system with dry nitrogen, evacuating and recharging with 24 ounces (680 grams) of R-134a refrigerant (see “SERVICE” section). (f) Final system leak test (see “Adjustment/Test” section). (g) Close and secure baggage panels that were removed. (h) Check system operation and fault codes (see “Description/Operation” section 21-50-00, section 4, pages 12-20). A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 420 Issue 6 21-50-00 G Heater/Defog Drive Actuators (see Figures 7 and 7a) 1 Position and install Heater and/or Defog Drive Actuator(s) onto Actuator Drive Plate located behind the co-pilot side panel, below the cockpit entry door. 2 Install actuator(s) to Actuator Drive Plate: a) For each actuator, install 3 of NAS1149F0363P washers (washer to be used between actuator and spacer) and 0587912 spacers between actuator and Actuator Drive Plate. Insert 3 of AN526C1032R18 screws through actuator, washer, spacer and Actuator Drive Plate, then secure screws with 3 of MS21044N3 nuts. Tighten hardware to secure actuator to Actuator Drive Plate. Install Defog Actuator cable into Defog Actuator rod end fitting and secure with set screw and Loctite® Threadlocker 242®. Install 2 of MS21919WDG3 clamps onto Defog Actuator cable. Insert 2 of MS35206-246 screws through clamp and Actuator Drive Plate, then install 2 of AN960-8 washers and secure with 2 of MS21043-08 nuts. Tighten hardware to secure clamps. Figure 7 “Heater/Defog Drive Actuators” A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 421 Issue 6 21-50-00 3 Install Actuator Drive Plate: a) Forward and aft sides of Actuator Drive Plate: Insert 2 of MS35206-245 screws through the forward side of the Actuator Drive Plate. b) Lower edge side of Actuator Drive Plate: Insert 2 of MS35206-245 screw through the lower edge of the Actuator Drive Plate. Tighten hardware, securing the Actuator Drive Plate to the aircraft. Figure 7a “Heater/Defog Drive Actuators” 5. Once the air conditioning system installation is complete and power is restored to the aircraft, use a clean source of ground power, connected to the aircraft according to the aircraft maintenance manual, power up the aircraft electrical system with the engine off and turn the climate control system “ON”, select “AUTO” and set the temperature to 55°F (refer to POH supplement FTA-010-2). Confirm that the defog air valve is fully closed and that the heater mixing box door is in the fully cold position with the climate control system set as instructed, above. Adjust actuator cables at either the defog air valve or the heater mixing box, as required, to ensure correct operation of the defog air valve and the heater mixing box. 6. Check system operation and fault codes (see “Description/Operation” section 21-50- 00, section 4, pages 12-20). A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 422 Issue 6 21-50-00 H Electronic Control Unit (ECU) (see Figures 8 and 8a) All EXCEPT G36 1 Position and install the ECU in the center cockpit pedestal. 2 Re-connect wiring connectors to ECU. 3 Install and tighten hardware securing ECU. 4 Check system operation and fault codes (see “Description/Operation” section 21- 50-00, section 4, pages 12-20). G36 1 Position and install the ECU behind the right hand sidewall of the aircraft, just outboard of the co-pilot rudder pedals (see Figure 8a). 2 Re-connect wiring connectors to ECU. 3 Press ECU against Dual Lock tape to secure unit. 4 Check system operation and fault codes (see “Description/Operation” section 21- 50-00, section 4, pages 12-20). I Aft Cabin Heat Switch and Indicator (see Figure 9) 1 Position and install the Aft Cabin Heat Switch and/or Indicator in the Aft Cabin Heat mounting plate and tighten hardware. 2 Re-connect wiring connectors to the Aft Heat Switch and/or Indicator.. 3 Install and tighten Screws securing Aft Cabin Heat mounting plate to ceiling. 4 Check system operation and fault codes (see “Description/Operation” section 21- 50-00, section 4, pages 12-20). J Cabin Temperature Sensor (see Figure 10) 1 Install and secure the screws retaining the Cabin Temperature Sensor in the center pedestal between pilot and co-pilot foot wells. Ensure spacer is captured between the Cabin Temperature Sensor and the grille on the back side of the center pedestal. 2. Connect wiring connector to Cabin Temperature sensor, noting clocking location on connector. 3. Position center pedestal side cover(s) and secure screws retaining cover(s) in place. 4 Check system operation and fault codes (see “Description/Operation” section 21- 50-00, section 4, pages 12-20). A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 501 Issue 3 21-50-00 AIR CONDITIONING SYSTEM– ADJUSTMENT/TEST 1. General The following provides removal and testing instructions for the Vapor Cycle System (VCS) air-conditioning system. 2. Leak Test Refrigerant WARNING Review warnings and cautions listed in MAINTENANCE PRACTICES- SAFETY section before leak testing the refrigeration system. If air conditioning system is not cooling properly, determine if system is fully charged. Refer to Pressure and Performance Diagnosis chart, section 7.8. If the system is empty evacuate and charge the system with 0.6lbs. (10oz. or 296 grams) of R-134a refrigerant. Refer to “SERVICE” section for Refrigerant Charging Procedure. To detect a leak in the system, perform the following procedures. • Operate the air conditioning system until operating temperature and pressures are achieved based on the existing refrigerant charge. This is done by operating the engine with the air conditioning on for 5 to 10 minutes. • Position the aircraft in a wind free work area. The absence of wind will aid in the detection of small leaks. • Remove engine cowling, condenser access panel, the receiver/dryer access panel and the evaporator housing cover prior to leak test to dissipate any accumulated refrigerant. Aircraft cabin doors must be left open during test operation. • With the engine NOT RUNNING, use an R-134a Electronic Leak Detector and search for leaks. Move probe slowly along the bottom side of lines and fittings, because R-134a is heavier than air. Fittings, lines, or components that appear to be oily usually indicate a refrigerant leak. • Inspect the evaporator core for leaks ƒ With the engine NOT RUNNING, set the Automatic Climate Control temperature to ”55°F (13°C)”, select “LO” for the blower speed and check for leaks in the air conditioning outlet vents. ƒ Inspect the evaporator drain tube outlet for the presence of refrigerant oil. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 502 Issue 3 21-50-00 A Evacuating Refrigerant System-General Notes Refer to “SERVICE” section for complete system evacuation procedures. WARNING Review warnings and cautions listed in MAINTENANCE PRACTICES- SAFETY section before evacuating refrigeration system. If the air conditioning system has been open to the atmosphere, it must be evacuated before the system can be charged. Moisture and air mixed with refrigerant will raise the compressor head pressure above acceptable operating levels, reduce system performance and potentially cause internal system corrosion resulting in severe damage. Moisture will also boil at near room temperature when exposed to sufficient vacuum. To evacuate the refrigerant system use the following procedure. • Connect a suitable charging station and manifold gauge set to the aircraft. • Open the low and high side valves and start the vacuum pump. When suction gauge reads 26in. Hg (660 mm Hg) vacuum or greater, close all valves and turn off vacuum pump. If system fails to reach specified vacuum, the system has a leak that must be corrected. If system maintains the specified vacuum for 30 minutes, start the vacuum pump then open the suction and discharge valves to evacuate the system for an additional 40 minutes, minimum. • Close all valves. Turn off and disconnect the vacuum pump. The system is now ready to be charged with R-134a refrigerant. Refer to “SERVICE” section. CAUTION: Do NOT overcharge the air conditioning system. This will cause excessive compressor head pressure, loss of cooling, noise and system failure. A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 503 Issue 3 21-50-00 B Charging Refrigerant System-General Notes Refer to “SERVICE” section for complete system evacuation procedures. WARNING Review warnings and cautions listed in MAINTENANCE PRACTICES- SAFETY section before evacuating refrigeration system. R-134a refrigerant is a hydro fluorocarbon (HFC) that does not contain chlorine. An R-134a refrigerant Recovery/Recycling Station that meets SAE standard J2210 must be used to discharge the refrigerant system. Refer to the operating instructions provided with the equipment for proper operation. The REQUIRED method of charging is to completely discharge and evacuate the system and recharge using a Recovery/Recycling Station approved for R-134a refrigerant. Refer to the operating instructions provided with the equipment for proper operation. After the air conditioning system has been tested for leaks and evacuated, a refrigerant charge can be injected into the system. The system capacity is 24oz. (680 grams). CAUTION: Do NOT Overcharge System NOTE: System charge is 24 ounces (680 grams) of R-134a A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 504 Issue 3 21-50-00 3. Pressure and Performance Diagnosis Condition Possible Cause Correction Low side and high side pressure 1. System refrigerant is low 1. Discharge, evacuate, leak test and low charge system Low side pressure high and high 1. Internal leak in compressor 1. Replace compressor side pressure low 2. Drive belt slipping 2. Tension or replace belt Low side and high side pressure 1. Condenser fins obstructed 1. Clean condenser fins High 2. Air in refrigeration system 2. Evacuate, leak test and charge system 3. Condenser fans inoperative 3. Troubleshoot condenser fans 4. Refrigerant system overcharged 4. Recover refrigerant and recharge Low side pressure low and high 1. Restriction in refrigerant hose 1. Check hoses for kinks and side pressure high 2. Restriction in receiver-dryer replace if necessary 3. Restriction in condenser 2. Replace receiver-dryer 4. Expansion valve is defective 3. Replace condenser 4. Replace expansion valve Low side and high side pressures 1. Check for correct cooling at 1. If temperature is correct check normal (inadequate cooling) evaporator assembly outlet for obstruction or leak in cabin ducting Compressor noise 1. Internal compressor damage 1. Replace compressor 2. Refrigerant system overcharged 2. Recover refrigerant and recharge 3. Loose compressor mounting 3. Tighten compressor mounting bolts 4. Loose or worn compressor drive to correct torque values belt 4. Tension or replace belt Excessive vibration 1. Incorrect belt tension 1. Tension or replace belt 2. Compressor loose 2. Tighten compressor mounting bolts to correct torque values 3. Refrigerant system overcharged 3. Recover refrigerant and recharge 4. Drive or idler pulley worn 4. Replace defective pulley Condensation leaking inside 1. Evaporator drain plugged or 1. Clean drain hose and check for Aircraft kinked proper installation Frozen evaporator coil 1. Faulty evap temp sensor 1. Replace evap temp sensor 2. Obstructed evaporator coil 2. Removed obstruction A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 505 Issue 3 21-50-00 NOTE: The pressure values listed in this document vary according to environmental factors and are to be used as a guideline for further troubleshooting, not as a sole source. NORMAL 60 100 20 B 40 D F 80 E A-Normal System B-Low Refrigerant Charge C-Refrigerant overcharge or Receiver/Dryer restricted D-Expansion Valve closed E-Expansion Valve stuck open F-Inadequate Compressor performance NOTE: Chart should be considered as an aid to diagnostics not a single source. 300 High-Pressure 200 A C Ambient Temperature 70°F (21°C) E 100 20 40 D 60 F 300 High-Pressure 200 A-Normal System B-Low Refrigerant Charge C-Refrigerant overcharge or Receiver/Dryer restricted D-Expansion Valve closed E-Expansion Valve stuck open F-Inadequate Compressor performance NOTE: Chart should be considered as an aid to diagnostics not a single source. B NORMAL A C Low-Pressure 80 Ambient Temperature 80°F (27°C) A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 506 Issue 3 21-50-00 A-Normal System B-Low Refrigerant Charge C-Refrigerant overcharge or Receiver/Dryer restricted D-Expansion Valve closed E-Expansion Valve stuck open F-Inadequate Compressor performance NOTE: Chart should be considered as an aid to diagnostics not a single source. 60 100 200 High-Pressure 20 NORMAL B A D 40 F 300 C 80 E Low-Pressure Ambient Temperature 90°F (32°C) High-Pressure 100 200 A 20 D B NORMAL F 40 60 300 A-Normal System B-Low Refrigerant Charge C-Refrigerant overcharge or Receiver/Dryer restricted D-Expansion Valve closed E-Expansion Valve stuck open F-Inadequate Compressor performance NOTE: Chart should be considered as an aid to diagnostics not a single source. C Ambient Temperature 100°F (38°C) Low-Pressure 80 E A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Page 601 Issue 4 21-50-00 AIR CONDITIONING SYSTEM– INSPECTION/REPAIRS 1. General The following provides inspection and Repair information for the Vapor Cycle System (VCS) air-conditioning system. 2. Inspection A 100 HOUR/ANNUAL INSPECTION Inspections shall consist of the compressor drive belt and pulleys, hoses and air ducting/vents, wiring, and component attachment. • The compressor drive belt shall be inspected for chafing and/or wear. Replacement is considered to be “on-condition”. • The compressor drive belt pulleys shall be inspected for security, tightness and rotational smoothness and freedom. • The refrigerant hoses shall be inspected for chafing, leaks and security. Leaks will manifest themselves as an “oily” spot most common around connections. • The air ducting and vents shall be inspected for intake and outlet obstructions or damage. Vent hoses shall be inspected for security and chafing. • Inspect the OAT sensor located at the forward right of the engine for security. Inspect the wiring for security and condition. • Inspect under the instrument panel all wiring and connectors routed from the ECU to the heat actuators. Inspect the condition and security of the heat actuators. • Inspect all refrigerant hoses to include, the lines routed behind the left wall interior panel for security and condition, look for “oily” spots. Ensure pitot static tubing is separated from the smaller refrigeration hose (p/n 2214513). • Inspect the air duct connection at Sta. 190 for condition and security. • Inspect the evaporator (sta. 190) and the condenser (sta. 215) for condition, security and cleanliness. Inspect the attaching structure and attaching hardware for condition and security. Inspect the receiver/dryer and attached wiring (sta. 207) for condition and security. • Inspect the condenser exhaust screen and plenum for obstructions and security. Inspect the attached doubler for condition and lose or missing rivets. • Inspect the condenser air intake for obstructions and security. • Inspect to insure that the evaporator drain tube is clear of obstructions and that the drain line in not kinked. DRAFT F33A, A36 Wiring Diagram (Ref FTA-600-2) DRAFT F33A, A36 Wiring Diagram (Ref FTA-600-2) cont. DRAFT F33A, A36 Wiring Diagram (Ref FTA-600-2) cont. G36 Wiring Diagram (Ref KPAK 2214305) DRAFT G36 Wiring Diagram (Ref FTA-600-2) DRAFT A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Issue 3 THIS PAGE INTENTIONALLY LEFT BLANK DRAFT A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Issue 3 SECTION III INSTRUCTIONS FOR CONTINUED AIRWORTHINESS (ICA) DRAFT A/C SYSTEMS LLC BEECH F33A/A36/G36 BONANZA INSTRUCTIONS FOR CONTINUED AIRWORTHINESS AND MAINTENANCE MANUAL SUPPLEMENT FTA-010-3 Issue 3 Maintenance Requirements - Instructions for Continued Airworthiness A/C Systems LLC 138 Sherron Dr. Dickson, TN 37055 IFCA/MMS Issue: 3 “Modification of an aircraft and issuance of a new or amended Type Certificate (TC) Data Sheet or a Supplemental Type Certificate (STC) obligates the aircraft operator to include the following maintenance information in the operator’s Aircraft Maintenance Manual and the operator’s Scheduled Aircraft Maintenance Program as specified.” It is not the intention of this document to supersede any information in the aircraft manuals, except in those areas listed herein. The information in this document is presented in ATA-100 format; however, minor deviations may be encountered. For aircraft to be operated in the US “The Airworthiness Limitations section is FAA approved and specifies maintenance required under 43.16 and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved.” This cover sheet and the documents listed in numbered paragraphs 1. through 4. below constitute the ICA. 1. Maintenance manual information (system description, operation, location, maintenance, service, removal, installation, adjustment/testing, repair, and inspection) is contained in the Supplemental Maintenance Manual. 2. Wiring diagram information is also contained in the Supplemental Maintenance Manual. 3. This ICA does not generate any additional Scheduled Maintenance program tasks except for those inspections listed in the Supplemental Maintenance Manual, Section 05-00-00. The existing Aircraft Maintenance Manual, or any applicable Supplemental Aircraft Maintenance Manual, remain in effect for the applicable aspects of this STC. 4. The equipment added by this STC (ref: Air Cycle Air Conditioning System) are primarily on systems or components. Specific non-functioning components are to be removed and replaced. Re-installed components are to be operationally checked per the Supplemental Maintenance Manual, Section 21-50-00. Troubleshooting should be accomplished in accordance